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激光制造業(yè)亟需組建優(yōu)秀的激光加工團隊，大力普及激光加工技術(shù)，設立激光加工教學、科研和生產(chǎn)基地，加大相關(guān)技術(shù)同步研究，將機器人技術(shù)、仿真技術(shù)應用等大規(guī)模地應用到城市軌道車輛制造中，發(fā)展我國自主特色的激光加工設備以及加工工藝。激光加工技術(shù)在城市軌道車輛制造中的應用，包括焊接、切割、表面改性、打標、快速成型、打孔及微細加工等。文章以城市軌道車輛為研究對象，闡述了先進激光焊接、激光切割在城市軌道車輛制造和輪軌表面處理等的原理和特點，分析了目前激光加工技術(shù)在城市軌道車輛制造中的特點和應用前景，為縮短與國外先進技術(shù)的差距，加快軌道交通技術(shù)儲備提供參考。

城市軌道交通已成為現(xiàn)代城市公共交通的主動脈，具有運量大、能耗低、效率高、污染小、準點率高等優(yōu)勢。中國如今已成為全球城市軌道交通建設投入的主力軍，甚至連許多二線城市都具備了軌道交通建設的條件與需求。
隨著中國政府“十三五”規(guī)劃的提出，國家發(fā)改委已批復了多地軌道交通的規(guī)劃，到2020年投資預計將超萬億。目前城市軌道車輛制造行業(yè)中，激光加工制造技術(shù)備受矚目，其很大程度上提升了城市軌道車輛制造水平；輕量化與高速化的趨勢，也持續(xù)為其提出新方向、新課題。

由于中國的城市軌道交通起步較晚，因此為了縮短與國外先進技術(shù)的差距，應引進、研究和消化當前最新技術(shù)及設計思路，加快軌道交通技術(shù)儲備，探究激光加工技術(shù)在城市軌道車輛制造中的應用。車輛激光焊接車輛轉(zhuǎn)向架以及車體是城市軌道車輛上的關(guān)鍵構(gòu)成，材質(zhì)也經(jīng)歷了普通合金鋼、不銹鋼、鋁合金型材幾個階段。目前在城市軌道車輛制造中，逐步引入了激光焊接等新的加工工藝。

激光拼焊

激光拼焊是城市軌道車輛中最被看好的技術(shù)之一，屬于無接觸焊接，可將不同鋼種、厚度、表面處理的鋼板焊接成一個整體，區(qū)別于電阻滾壓縫焊，通過自由組合，使得構(gòu)件變輕，零件變少，不僅提高可靠性，為寬體車制造奠定基礎，同時也改善了焊接質(zhì)量，提高了鋼材收得率，并降低了生產(chǎn)成本。

激光組焊

激光組焊在城市軌道車輛車身制造中舉足輕重，通過雙件組焊、多件組焊，將已切割成形的各類車身構(gòu)件，焊接成白車身分總成，進而總裝成整車車身。激光組焊因其焊接強度高，可明顯改善車身強度、剛度及密閉性。焊接同時結(jié)合面小、變形小、焊接速度快、可焊材料范圍廣，適合于柔性化生產(chǎn)，投資效益好。但激光組焊技術(shù)也有明顯的缺點，如對夾具、被焊件、監(jiān)測精度等要求嚴格，焊接后檢測評價和返修困難，一次性投入大等。

激光-電弧復合焊

1) 不銹鋼車體制造。城市軌道車輛車體通常選用不銹鋼車體，由于電弧焊接后熱影響及變形等較嚴重，因此為改善外觀，過去常常進行涂裝作業(yè)，而現(xiàn)在則選用激光或電阻焊進行作業(yè)。

通過長期加工技術(shù)應用的實踐、積累及分析，不銹鋼接頭焊接技術(shù)規(guī)范、疲勞曲線、硬度、抗拉強度、屈服強度、等技術(shù)指標相繼被取得或檢驗，車體激光焊接樣件的制評亦完成。


2) 車輛轉(zhuǎn)向架制造。城市軌道車輛轉(zhuǎn)向架通常選用日本進口或國產(chǎn)的中厚合金鋼板材，同時多選用熔化極氣體保護焊。用于長直縫焊接的機械人手臂，已被各廠商所引進，來改善焊接穩(wěn)定性；而開具有不同規(guī)格的坡口，通常留較小鈍邊，以確保熔透。激光-電弧復合焊優(yōu)化焊接效率，顯示了激光和電弧的特點；同時減少了設備和人員投入，降低了焊接成本，并且可選較大鈍邊。


車輛激光切割

激光切割技術(shù)特性城市軌道車輛制造廠商已大量使用激光切割技術(shù)，其加工的產(chǎn)品有很多，如車體、內(nèi)裝板材、轉(zhuǎn)向架，常選用二維平面切割。激光可以加工出高精度、高切割斷面質(zhì)量的零件外形、輪廓和孔。

固體(或CO2)激光切割機通常適用于碳合金鋼、不銹鋼，同時也適用于鋁合金板，可達到理想斷面加工質(zhì)量和切割速度。以某企業(yè)為例，軌道車輛車體為不銹鋼，選用6 k W激光和剪板機對6 mm以下板材下料。車輛轉(zhuǎn)向架選用激光切割機對14 mm以下板材進行下料，其材料為Q345C低合金結(jié)構(gòu)鋼。

下料環(huán)節(jié)激光切割

城市地鐵機車制造首先要準備相關(guān)材料，這個階段激光切割技術(shù)尤為重要。激光切割與火焰切割相比，切割速度快、工件變形小、加工精度高、適用性強、節(jié)料省錢、經(jīng)濟適用[16]，因此激光切割技術(shù)已被廣泛用于軌道車輛制造中。以某企業(yè)為例，其高速動車組車體選用激光和剪板機對6 mm以下板材下料，材料為鋁合金板材及型材。車輛轉(zhuǎn)向架選用6 k W激光切割機對12 mm以下板材下料[17]。

 

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156-B32AA2 32 A Contactor

1746-ITB16 SLC 16 Point Digital Input Module

1786-TPRT2T C-Net TNC IP67 T-TAP/TNC-TNC RIGHT THICK

193-T1CC36 24.5-36 A IEC Bibllic Overload Relay

20-HIM-C5S PowerFlex Programmer Only HIM

2090-CSBM1DF-14AA50 Kinetix Cable Single DSL 2090-Series

20AC022A0AYYANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT075 Proficy GlobalCare Assist for CIMPLICITY HMI Server 75 I/O Runtime System

GP647IFSTRN00900 GCP iFIX Std HMI 900 I/O Run

IC600CB536RR Communications Control Module Type 2

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IC693UDR005RR 28 pt DC In/Relay Out/DC Out, AC Power Supply

IC756RDV001J-97 DV Development - Irix Op Sys Addt'l User, Japanese, Version 9.7

MicroLogix 1200 System 1762-L40AWA MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-ES SERVO ENCODER FEEDBACK EXPANDER

Distributed I/O 1794-IB16XOB16P 24 VDC COMBO MODULE, 32 POINTS

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Operator Interface D6195-6.5.1IT CONTROLVIEW 300 INSTALLATION MANUAL (ITALIAN)

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RSI Software Products 9324-RL0300ENE RSLOGIX 500 STANDARD CD-ROM

RSI Software Products 9301-2SE3503JPE RSVIEW32 RUNTIME 100K WITH RSLINX (JAPANESE)

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IC695DEM002 RX3i type 2 demo case. Demo includes CPU, power supply, Ethernet, bsimulator, output, high speed counter, analog combo, Universal analog, and digital servo modules. Demo also includes QuickPanel control/view

MTR-1216-N-D-E-0 MTR series NEMA 23 stepping motor. Winding connection type is determined by cable

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1492-SPM2D150 MCB Supplementary Protector 15 A

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150-F317NCDB SMC Flex Smart Motor Controller

1732E-IB8M8SOER ARMORBLOCK 8 POINT SOE INPUT

1771-VHSC 1771 Combination Module

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2090-CPWM7DF-10AA01 MP-Series 1m Servo Power Cable

2097-V31PR2 Kinetix 300 Servo Drive

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IC693MDL230LT 120 Vac Isolated Input (8 Points) (LT)

IC756CDV000E-97 DV Development - Compaq True64 Op Sys, English, Version 9.7

MSI-MGMT-25-43 Production Management Clients 25 Pack

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Communications 1787-PCABL PROBE CABLE FOR 1770KFD

Operator Interface 2711-NM13 2 MBYTE PC FLASH MEMORY CARD FOR PANELVIEW E TERMS

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2090-XXNPMP-8S15 MP-Series 15 m Length Power Cable

CBL-3C-MP-20 Power cable for MTR-3S43-G or MTR-3S45 or MTR-3S46 or MTR-3S60-G series servo motors. 20 feet

GF-0675R Connecting FlashCable to Fowler Trimos Vertical, Horizontal.

IC200TBX464 Tool box, Micro 64, stepper motor, PowerCube amplifier and software. Includes (IC200UDD064) 24VDC In/24VDC Out, DC Power Supply, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in, stepping motor amplifier (IC800PCUB00300), stepping motor

IC646TBSPMSS100 Smart Process Monitoring SPC+ server 100 KPIs

IC647NTS010 CIMPLICITY HMI Terminal Services 10 User Pack

IC693ALG220 Analog Input, Voltage (+/-10VDC, 12bit), 4 Channels

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1585D-M4UBDF-8 Ethernet Media M12, Patchcord

1756-IF8IH ControlLogix 8 Pt A/I HART Isolated

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2090-CFBM4DF-CDAF50 MP-Series 50m Feedback Cable

2090-KPBM7-12AA MP-Series Power and Brake Connector Kit

BC646EXO365 Solution Provider additional OP License

GC646TRT935 Proficy GlobalCare Complete for Server 35,000 I/O Runtime System

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IC752PBMU11 Profibus Master/Scanner for ControlStation CE Iix

MTR-3S65-G-R-B-E-SRR Servo Motor 24V Brake, Seal

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DMC2210A

1492-JG70 IEC 1-Ckt Feed-Through Grd Blk 70mm

1492-WM4 IEC Term Blck 8x47.6x41mm Screw

軟啟動器 3RW44231BC46

緊湊型信號模塊 6ES7 521-1BL10-0AA0 DI 32：數(shù)字量輸入模塊，DI 32x 24VDC BA, 25mm 模塊，含前連接器

1585-C4EB-S300 Ethernet Cable Spool PVC Red 300m

1746-NT8 SLC 8 Point Digital Input Module

1788-EN2DNROM EtherNet/IP-DNet Bridge - On Machine

193S-EESP E1 Plus 5.4-27.0 A Overload Relay

20-PP01049 FAN FOR FAN INVERTER PWRFLEX HIGH PWR

2090-CSBM1DF-14AF25 Kinetix Cable Single DSL 2090-Series

20AC030A0AYYANC0 PowerFlex 70 AC Drive 30 A at 15 kW 20A

GC-8455-SW-CF MTL8000 Configurator Software (Serial cable included)

GPA-602-PCI LVDT b system for PCI (End User).

IC600CR620RR 19 inch Series Six Plus CPU Rack w/o Power Supply (11 Slots)

IC647HSTCSEO500KM eSignature Option for Historian - Enterprise Corporate Server 500000 Points (M4 Key)

IC647WFLPCA Proficy Workflow - Production Corrective Action Templates and Reports

IC694ALG223CA Input module, analog 16 point single ended, current.

IC756RDV010K-99 DV Draw Development on IRIX Op Sys, Korean, Version 9.9

MicroLogix 1200 System 1762-OW16 16 POINT VAC/VDC RELAY OUTPUT MODULE

PLC-5/1771 System 1771-QA STEPPER MOTOR POSITIONING ASSEMBLY W/ 1771OJ,-M1

Distributed I/O 1794-OB32P 24 VDC OUTPUT MODULE, 32 POINTS

Communications 9399-INTSOLUG INTERCHANGE FOR SOLARIS USER GUIDE

Support 6200-AGA3S SUPT RENEWAL CONTRACT FOR 6200AGA3

Support 9358-BIZDME1S SUPT RENEWAL CONTRACT FOR 9358BIZDME1

Support F1771-ASBSERD FIRMWARE UPGRADE FOR 1771-ASB I/O MODULE

RSI Software Products 9324-RL53U7ENE RSLOGIX 5 STD TO PRO UPGRADE

RSI Software Products 9301-2SE350FRU1R RSVIEW32 RUNTIME 32K-100K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-HSTS2400U1 UPGRADE: IN-SUPT: HISTORIAN 150 TO 32K TAG

Motion Control 8720SM-005S1BAS3 SPARE PART ONLY - GMS ITEM

78004657 Target Two-Axis Motion Controller Expansion Card Kit

IC200MDD847LT MIXED OUTPUT RELAY 2.0A PER PT ISOLATED 8PT / INPUT 240VAC GRP 8PT (LT)

IC697ACC806 I/O Cable (32 conductor) for IC697Vxxxxx modules. Ten feet long